Top service TSUV Gyratory Crushers Safer, smarter and more

Top service TSUV Gyratory Crushers Safer, smarter and more powerful crushing
WE DISCOVER POTENTIAL
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More power without a significant increase in crusher footprint Greater capacity without compromising on performance Optimised speed to balance throughput and wear rates Enlarged feed opening for greater flexibility Service through the top, significantly reducing safety risks Integrated, smart controls, including wear compensation and
automatic mantle adjustment to maximise crushing efficiency Potential to connect to your mobile device for real time status
and alerts, wherever you are Liner optimisation for the lowest wear cost per tonne
It’s the most efficient gyratory crusher on the market, designed to help your mining operation reach its full potential.
Are you doing more work for the same yield? Your energy bill is higher. Your maintenance costs are higher. Your health and safety risks are higher. That’s the reality of crushing low-grade ore.
At the same time there is pressure to reduce the environmental impact of your operation. Bring down energy consumption. Increase efficiency. And of course, always, protect your personnel from harm.
It’s time for next-generation crushing We can’t change the nature of your deposit. But we can change the way you crush it. Our Mark V Top Service Gyratory Crusher – the TSUV – brings you:
The lowest cost per tonne of product processed
Crushing just got harder. With low grade ore deposits requiring higher power and higher throughputs than ever before, you need a crusher
that can take the impact – without compromising on efficiency. With more power and greater capacity, the digitally-enabled TSUV
is the world’s most OPEX and CAPEX-efficient gyratory crusher.
Ultra-heavy duty
Key benefits
With mining companies increasingly turning to low-grade deposits to meet market demand, the pressure
on crushing operations is greater than ever.
It’s a hard rock life
World copper demand increases as copper deposit grades fall
4 5TSUV Gyratory Crushers TSUV Gyratory Crushers
Safety, reliability and performance The TSUV is our latest generation gyratory crusher, following the successful rollout of our Top Service (TS) and Top Service Ultra Duty (TSU) models. The unique design emphasises safety, easy maintenance and efficient crushing performance.
Unlike other gyratory crushers, which require workers to get in underneath the crusher to perform maintenance tasks – a high-risk operation – the TS range allows service and maintenance to be carried out from above. The eccentric assembly, bushings and hydraulic piston are easily accessible and removed through the top of the crusher, hence the name ‘Top Service’. Not only is this much safer than the bottom service crusher design, it also increases the speed and simplicity of maintenance work, reducing costs and boosting availability.
In addition to safety and the reduced maintenance burden, the TS gyratory crushers are built for strength, durability and the ability to adapt to the various requirements of mine operators.
Harder, better, faster, stronger The Mark V design builds on these strengths and adds even more power, capacity and flexibility. We have re-engineered the entire crusher to deliver advanced crushing efficiency with only a nominal increase in footprint.
It’s also safer than ever before. The all-new self-aligning main-shaft negates the need for service personnel to be working underneath a heavy suspended load. Previously the 100+ tonne fully-dressed main-shaft had to be guided into the eccentric assembly by hand. With this new development the shaft aligns automatically, dramatically reducing risk.
To offer even greater potential to optimise performance, the TSUV is digitally enabled – giving you more control over operations and availability. This is a game-changer. The ability to make fine adjustments to wear compensation, track equipment trends and instantly detect crusher obstructions will enable increased uptime, optimum equipment life and a significantly reduced risk of unplanned downtime. Additionally, our integrated control system incorporates all the required safety and interlock features to keep your operators safe.
Mining has a long history – and so do we. Our commitment to optimising the comminution process with quality crushers dates back to the Traylor and Fuller-Traylor gyratory crushers of
the early 1900s. Since then, our crushers have continuously withstood the harshest demands of the world’s mines and rock quarries. Through constant improvements in engineering, we have
earned our place as a proven and preferred crusher supplier throughout the industry.
A chip off the old rock The evolution of a master crusher
MK I MK II MK III
HighLow
MK I MK II MK III MK IV MK V
HighLow 0
MK I MK II MK III MK IV MK V
HighLow
Notes
Bulldog 1905 Mk I 18 200 150 1 : 1 2.5 : 1 48 Side discharge - belt driven (flat, later V-type)
1910 Mk I 48 1.200 225 1 : 1 2.5 : 1 48 Maintenance intense (multi-daily)
1919 Mk I 60 2.000 330 1 : 1 2.5 : 1 48 Grew over 50 years. Became basis for all other designs
1950 Superseded Eventually, over 2,400 sold
TC 1950 Mk II 60 3.000 375 1 : 1.5 3.5 : 1 30 Circular discharge - belt driven (flat, later V-type)
1969 Mk II 72 3.400 525 1 : 1.5 3.5 : 1 30 Hydraulic adjustment introduced in early 60's
1990 Superseded
NT 1990 Mk III 60 x 113 4.500 750 1 : 1.7 4.0 : 1 17 Circular discharge - shaft driven
2005 Mk III 60 x 113 6.000 1.000 1 : 2.0 4.0 : 1 17 Incorporation of FEA and modern controls
2013 Still current Modularised and simplified components
TSU 2006 Mk IV 63 x 114 8.000 750 1 : 1.7 4.5 : 1 5 Circular discharge - shaft driven
2009 Mk IV 63 x 118 10.000 1.200 1 : 2.3 4.5 : 1 5 Incorporation of FEA and modern controls
2013 Still current Eccentric serviced from top
TSUV 2020 Mk V 72 x 130 15.000 1.500 1 : 2.7 4.5 : 1 4 As TSU but more enhancements. Rotable shells, self-aligning main-shaft
Our next generation model 1,500 kW and capacities up to 15,000 mtph
1905 Bulldog MK I
1950 TC MK II
1990 NT MK III
2006 TS MK IV
2020 TSUV MK V
We understand that to cope with new challenges, you need new technology. It’s why we re-engineered the entire TSUV, rather than adding features to the previous model. Every part of the Mark V has been strengthened and improved to give you greater crushing efficiency and a low total cost of ownership (TCO). We’ve instilled all our knowhow and process experience into the design to bring you:
Higher power – Improved power handling capabilities allow you to process more material as ore yields decline, enabling you to remain competitive. The crusher footprint has only nominally increased but maximum power handling is now up to 1500 kW.
Higher capacity – Improved capacity throughputs make use of the additional power available without compromising on setting or product size. You get the same product – but more of it.
Optimised speed – We’ve optimised eccentric speeds to ensure maximum throughput without incurring excessive wear rates. This is a finely balanced equation, based on extensive R&D work, which together with the new service and operational features, gives you the lowest possible cost per tonne of material processed.
Enlarged feed opening – For those customers with ‘slabby’ or ‘blocky’ materials, we have introduced extended topshells to give you larger feed openings. These are optional for all machines in the TSUV range.
Liner optimisation service – This service ensures wear maintains the desired nip angle, which keeps power at a constant range and thus optimises throughput.
Easier maintenance – Up to 74% reduction in planned maintenance time means more time in production, increasing productivity and boosting your bottom line.
Integrated controls – Our advanced control system includes KPI dashboards, built-in trending, power and PSD wear compensation, automatic lowering of the mantle and camera/laser detection of oversize boulders and bridging. These are significant developments that will enable you to increase reliability and reduce the risk of an unscheduled stop.
As ore grade decreases and the industry seeks to crush ever harder material, crushers have to rise to the challenge. You need more power to handle greater capacities. You need the
kind of hard-wearing, durable system that can manage ore with a BCWi into the 50s. But more power typically means more wear and you can’t afford more outages – you need less.
With great power comes greater throughput
Raising the bar Are you crushing large lump ore or “blocky” material? Our optional High-Flow Spider features a raised design that increases the feed height under the spider arms by as much as 200 mm, allowing plenty of room for larger material to enter the crushing chamber.
While bridging can never be fully eliminated, this option, together with our oversize feed particle size detection system, ensures it is minimised and your crusher maintains maximum availability.
+7% Greater speed
+10% Increased capacity
In this latest generation, speed is increased by a further 7%. This, in conjunction with the larger mantle diameter, equates to approximately a 10% capacity increase – and not at the expense of setting.
Higher power handling – maximum power now up to 1500 kW Rotable top and middle shells as standard Self-aligning main-shaft as standard on all TSUV models
(a significant advantage to health, safety and availability) Digitally enabled controls and condition monitoring Designed to crush even the hardest ore
1. The bar-type spider’s four-bolt design reduces the amount of time required for removal. Further, its rectangular design reduces the overall amount of space necessary during maintenance.
2. Spiral bevel gearing allows for larger installed power on the crushers.
3. The countershaft assembly is designed to allow for fine adjustment of gear mesh during installation. It includes self-adjusting bearings that require no maintenance or pre-load.
4. Eccentric and hydraulic piston now accessed from the top, are serviced faster, more efficiently, and safer than a traditional bottom service gyratory crusher.
5. Threadless main-shaft design improves strength by minimising peak stresses during demanding crushing operations.
6. One-piece integral main-shaft standard on all sizes eliminates core shrink fit and reduces any loose core downtime.
1. Bar-type spider 2. Spiral bevel gearing 3. Countershaft assembly 4. Top serviceable eccentric
and hydraulic piston
5. Threadless main-shaft design 6. One-piece integral main-shaft 7. Integral main-shaft lifting eye 8. Grease spider lubrication 9. Bronze spider bushing
10. Top shell wear plates 11. Dust seal pressurised chamber 12. Bottom shell view ports 13. Identical lube and hydraulic oil
TSUV – the Mark V gyratory crusher
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7. Integral main-shaft lifting eye ensures that it is stronger and never misplaced.
8. Grease spider lubrication is simpler than oil lubrication and easier to maintain.
9. Bronze spider bushing provides improved life and better impact resistance than a cast iron spider bushing.
10. Top shell wear plates are designed to be easily replaceable, better fitting and leading to faster dump pocket clean-out.
11. Pressurised dust seal minimises particle ingress and ensures that oil stays clean of contaminants.
12. Bottom shell view ports allow maintenance personnel to view crusher shell liners and check for wear.
13. We utilise identical oil in both the hydraulic and lubrication systems, ensuring that if cross-contamination occurs there is no need to flush out the system.
Get out from under the crusher Standard gyratory crushers require personnel to get beneath the crusher, a confined and hazardous workspace where they are at risk of:
Falling debris from above Higher exposure to pinch points Increased exposure to electrical hazards Inhaling harmful dust Exposure to noxious gases
When risk becomes reality, the consequences are devastating. Why take the chance when there is a better, safer option?
When we introduced the 'Top Service' model in 2006, we became the first supplier on the market to prioritise safety in this way. Still, no other vendors offer a fully top service option.
The TSUV takes that commitment to safety a step further with the creation of the self-aligning main-shaft. No more flawed installs and damaged seals and, most importantly, no need for service personnel to work under dangerous suspended loads.
Reducing risk Even in the best conditions, maintenance is still a hazardous job. So we’ve worked hard to streamline performance and optimise operating conditions to minimise the need for maintenance.
Advanced controls monitor the crusher and track trends to help you develop a more proactive maintenance strategy, putting an end to those stressful, dangerous unplanned shutdowns.
Fine adjustments for wear compensation ensure you get the most from your wear liners, extending the time between maintenance stops.
Automatic detection of oversize boulders and bridging reduces the need for manual inspection.
Safer operating as standard The latest integrated control system includes multiple OEM design interlocks to ensure the safety of both people and machinery. The system allows you to set user access levels to operating parameters and keeps a log of user events. The easy-to-use configuration and local language options simplify operations and help avoid mis communications. In fact, the TSUV’s control system operates at the highest industrial safety standard for E-Stop and communications.
All of these things combine to give you simpler maintenance that reduces planned downtime by up to 74% compared to previous generation models. That’s a significant reduction in your risk factor.
'Top Service' concept eliminates the dangers associated with working beneath a crusher
New rotable shell arrangement enables quick relining in a workshop
Self-aligning main-shaft negates the need for service personnel to work underneath a heavy suspended load
Higher reliability = fewer maintenance events Updated manuals to give guidance on safe working procedures Full set of OEM design interlocks for personnel and machine
protection
12 TSUV Gyratory Crushers TSUV Gyratory Crushers 13
Get operational and asset health insights 24/7 with the digitally-enabled TSUV. Minerals processes are faced with a number of challenges. Securing the safety of your personnel. Reducing your environmental impact. Increasing productivity, in spite of lower grade ores. And creating quality products that are able to compete in a difficult landscape. Digital technologies give you greater control in all areas, enabling you to maximise your returns in a safer, more sustainable manner.
But what does ‘digitally enabled’ mean for your crusher? It means you have the option to connect your TSUV to our digital eco system, giving you the benefits of both our technologies and our experience. We offer a range of services geared towards maintaining asset health and optimising performance, many of which can be carried out remotely, saving both time and money.
Maximum reliability The TSUV’s advanced control system gives you a 24/7 view of performance metrics, enabling you to increase reliability. Also, with further condition monitoring feedback and controls, you can get proactive about maintenance, minimising the risk of unplanned downtime.
The TSUV comes with multiple sensors as standard to monitor oil, lubrication, vibration and more.
A life tracker enables you to analyse oil, mantle and concave conditions, plotting trends and helping you make the best decisions for greater productivity.
As a connected machine, you also have the option for remote support and troubleshooting with FLSmidth 24/7 Global Remote Service Center.
Tracking and trending operating parameters enables you to continually adjust and optimise performance for the maximum return with minimum waste. The control system has built-in trending, historical data, alarms and events, stored locally for 6 months. The KPIs dashboard is clear and easy to interpret, enabling you to visualise performance levels at any given time at the touch of a button – and with our mobile app, SiteConnect, you don’t even have to be onsite to check on your crusher.
Smart control systems reduce maintenance costs and extend equipment life
SiteConnect Want to know what’s going on when you’re not on site? Stay connected with our mobile SiteConnect app for iOS and Android. View your asset performance and health data, no matter where you are, so that you can make the best decisions for your plant and equipment, promptly and with confidence.
Improved visibility of plant and equipment performance Optimised asset management Quicker response to unplanned events
UM
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Discharge diameter
Range and major dimensions
Model Motor (kW)
(Low – Standard) Weight
(mt) B C D E F H L M S T U W X
900 x 1500 375 - 450 90 2,507 2,186 4,245 150 3,923 2,687 2,770 3,451 2,300 805 3,259 820 1,334
1100 x 1500 375 - 450 108 2,507 2,186 4,453 150 4,136 2,898 2,770 3,650 2,300 805 3,457 705 1,334
1100 x 1900 450 - 600 147 3,343 2,843 5,717 150 5,136 3,376 3,645 4,470 3,080 1,139 3,966 1,228 2,068
1300 x 1900 450 - 600 175 3,343 2,843 5,998 150 5,414 3,641 3,645 4,728 3,080 1,139 4,207 1,056 2,068
1400 x 2200 600 - 750 250 3,900 3,400 6,716 150 6,102 4,177 3,850 5,568 3,599 1,250 4,836 1,275 1,973
1600 x 2200 600 - 750 298 3,900 3,400 7,046 150 6,433 4,505 3,850 5,889 3,599 1,250 5,130 1,096 1,973
1600 x 2600 750 - 1,000 391 4,850 4,250 8,029 150 7,139 4,877 4,975 6,770 4,171 1,500 6,325 2,635 2,981
1800 x 2600 750 - 1,000 474 4,850 4,250 8,423 150 7,526 5,260 4,975 7,160 4,171 1,500 6,710 2,266 2,981
1600 x 3000 1,000 - 1,200 522 5,450 4,850 8,770 150 7,929 5,408 5,215 6,574 4,775 1,670 6,320 2,468 2,780
1800 x 3000 1,000 - 1,200 608 5,450 4,850 9,200 150 8,318 5,833 5,215 6,953 4,775 1,670 6,705 2,122 2,780
1600 x 3300 1,200 - 1,500 554 5,450 4,850 8,631 150 7,539 5,001 5,350 6,900 4,780 1,670 6,416 2,538 3,060
1800 x 3300 1,200 - 1,500 654 5,450 4,850 9,055 150 7,948 5,394 5,350 7,297 4,780 1,670 6,807 2,183 3,060
Model 4 in
1100 x 1500
1300 x 1900
1600 x 2200
1800 x 2600
1800 x 3000
1800 x 3300
Notes: All capacities based on material with 1.65 t/m3 bulk density and Bond Crushing Work Index of 13 kWhr/mt. Minimum and maximum numbers based on Fine and Coarse feed gradations. Fine: F80 = 450 mm. Coarse: F80 = 700 mm.
OSS
CENTRAL CONTROL ROOM Monitor and control your single crusher or entire plant from one central control room – onsite or remotely.
INTERNET AND CLOUD SOLUTIONS Connect your single crusher or entire plant to our secure cloud infrastructure. It seamlessly integrates data and signals, enabling greater visibility to identify operational improvements or potential bottlenecks that may impact productivity. Access your data anytime and anywhere – even on your mobile device.
GYRATORY CRUSHER
CYBER SECURITY
REMOTE OPERATIONS AND SERVICES Protect your assets by monitoring or controlling your entire plant or single crusher. The FLSmidth 24/7 Global Remote Service Center makes our expertise and know-how available to maximise your performance.
EQUIPMENT MONITORING Get easy and direct access to information on your crusher health and performance with our intuitive HMIs or on your mobile device.
Digitalizing the crushing circuit
To increase productivity in your mine, we provide a strong portfolio of digital solutions and services that connect, monitor and optimise performance of your assets. This is the smart
way to increase your output, reduce operational costs and reduce energy usage.
CONNECTIVITY
Monitor, control and optimise remotely Connecting your crusher to the internet via our secure infrastructure is the prerequisite for harvesting the benefits of digitalisation.
CRUSHER HEALTH
Maximise the availability of your crusher Online condition monitoring of equipment and wear parts protects your crusher and mitigates risks to ensure optimal crusher reliability.
PERFORMANCE OPTIMISATION
Boost your productivity Our digital solutions uses data intelligence to optimise your crusher performance, boost your productivity and reduce your energy usage.
ECS/Product Control Integrated product control enables faster commissioning, fewer programming errors and better overall performance. We have embedded our extensive knowledge of how best to operate and control the crusher into our state-of-the-art control system. The integrated controls also provide you with the “ecosystem” for plug and play future upgrades and services.
SiteConnect™ Real-time data on your mobile device. Instant notifications in case of unexpected events and live access to performance data.
24/7 Global Remote Service Center Reduce unplanned downtime through insightful analytics and 24/7 monitoring by crushing experts.
Cyber Security Keep your connected IT updated, safe and unbreachable. Cyber security is an integrated and fundamental capability of our digital portfolio.
Crusher Sensors Multiple sensors to monitor oil, lubrication, vibration and more.
Life Tracker Enables you to analyse oil, mantle and concave conditions, plotting trends and helping you make the best decisions for greater productivity.
Augmented Field Engineer Allows our engineers to remotely assist with your operational issues. A hands-free remote collaboration tool enables you to share vision of your equipment with our field service technicians. Results in faster resolution of incidents, reduced cost of service delivery and increased availability.
Online Condition Monitoring Services We use secure and advanced cloud analytics, coupled with our local and global experts, to provide you with actionable insights to avoid losses associated with unexpected downtime and breakdowns.
ECS/UptimeGo Get insights to identify causes of equipment failure and eliminate downtime root causes.
Wear Compensation Maintain product consistency and quality even as your liners wear. Your operators never again have to guess when to adjust your OSS setting. The wear compensation option enables the crusher to automatically adjust the OSS as the liners wear.
Auto Lower Protect your crusher and your throughput with our quick-reacting auto lower feature. When you run into harder ore or changing ore bodies your crusher will adjust automatically based on your configured power and pressure settings.
Particle Size Direct Measurement Use direct measurement of your crusher output to further optimise your crusher performance.
Oversize Feed Analyse the crusher feed to detect oversize material. Reduce the chance of damaging your crusher as well as the potential loss of production do to oversize material being jammed in the crusher.
Bridging Increase the efficiency of your crusher operations by automatically identifying bridging in the crusher feed, alerting the operator to hold further feed until the bridging event has worked through the crusher.
ECS/Plant Data Management Transform process and quality data into real-time operations and get the most out of your plant and equipment.
On demand information in the control room or on your mobile
Expedite remote support Enable faster decisions and actions
Real-time insights available to top management
Increase uptime and availability by decreasing unplanned breakdowns
Maximise productivity and reliability Reduce environmental impact Cut operating costs Control and optimise operations
Key benefits of a connected crusher
Taking asset health to the next level with online
condition monitoring services Our online condition monitoring services combine digital technologies with process expertise. It’s like having a team of specialists onsite whose sole focus is optimising your crusher’s performance. Condition monitoring sensors automatically send data to our experts who then analyse it and propose action plans – this could be anything from reacting to an alarm within the system, to identifying energy saving opportunities.
Service packages can be tailored to your needs in line with your process goals, such as reducing downtime or improving efficiency.
Remote troubleshooting With experts on hand via video, telephone, email and even our Augmented Field Engineer (a hands-free tablet class wearable computer for service personnel) remote troubleshooting can be carried out as a one-off service or as a package covering one or multiple assets.
Downtime analysis software When stoppages happen, it’s vital to know what went wrong. Finding out what caused your plant and equipment to fail is the first step to preventing the same thing happening again in the future. Our downtime analysis software, ECS/UptimeGo, gives you the insight you need to identify what causes the equipment to fail and improve your processes for the future.
3D liner scanning and optimisation Maximise your crusher liner performance with our 3D liner scanning and optimisation service. Our chamber scanner uses laser technology that is capable of recording up to 50 million data points of the liner profile at accuracy levels physical measurements cannot achieve. It can easily be performed within planned maintenance and inspection schedules. Our experts compile, analyse and interpret the raw scanned data, then discuss wear life estimations, shutdown planning, and opportunities for improved operating procedures with you.
360°
ECS/UptimeGo includes the capability to:
Document what occurred in the lead up to stoppages Perform Pareto analysis Track maintenance KPIs Provide automatic downtime reports Quantify the cost of the stoppage on a plant and
department level
This enhanced visibility of downtime metrics enables you to eliminate root causes of downtime and increase equipment availability.
"Unplanned downtime costs the mining industry billions of dollars each year" Predictive maintenance can result in up to 75% reduction in breakdowns.
Key benefits Plug and play – no need for
additional sensors Proactive notifications on critical
failures Severity assessment and monitoring Reduced probability of unplanned
breakdowns Priority in quotation for add-on
services
You don’t need more data – you need insights
Our condition monitoring service combines data, technology and expertise to deliver you reduced downtime, greater reliability, better margins and more sustainable operations. We offer you two levels of online condition monitoring services:
Key benefits ‘Level I package’
+ Significant, additional coverage
to predict failures on critical components such as bearings, gears and more. Results in further reduced risk of downtime
Level I package EXSISTING SIGNALS
Level II package ADDED SENSORS
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Condition monitoring moves you from reactive to proactive maintenance.
Service package level
Overload monitoring
General overload warning
All these features are monitored by the smart control system. The aim is to avoid long-term
cumulative overload damage to bearings, frame, eccentric main-shaft , gears and drive
Yes Yes
Liner wear Yes Yes
Excessive tramp Yes Yes
Excessive reduction No Yes
Excessive fines No Yes
Crusher bearings
Yes Yes
2 Outer eccentric bushing Yes Yes
3 Inner eccentric bushing No Yes
4 Main-shaft wear rings No Yes
Vibration 5 Countershaft bearings Proactive component replacement at next planned shutdown before unexpected catastrophic failure
No Yes
Oil lube system
7 Pump wear
Proactive lube system adjustments to avoid nuisance crusher auto shut down
Yes Yes
9 Reservoir level monitoring Yes Yes
10 Flow split monitoring Yes Yes
11 Cooling system optimisation Yes Yes
12 Oil contamination monitoring Increase lube system component and bearing life as a result of improved oil cleanliness quality and dust seal system monitoring
No Yes
Grease lube system
14 Grease level monitoring Avoids nuisance trips from low grease level. Ensures adequte grease flow to spider bushing
Yes Yes
Hydraulic system
interrupted OSS crusher adjustment
17 Reservoir level monitoring Yes Yes
Leakage monitoring Prevent main-shaft drift and oversize product Yes Yes
18 Piston seal damage Allows proactive oil replacement thereby extending hydraulic system component life
Yes Yes
19 Oil contamination monitoring No Yes
Liners 20 Wear monitoring Optimises liner procurement and changeout planning Yes Yes
100% 65%
90% 90%
Digitalisation enables performance optimisation
From wear compensation to particle size distribution, digital technologies are driving performance improvements.
Built in tools extend liner life Innovative new tools enable you to get the maximum return on your liners:
Power Wear Compensation: Fine adjustments for wear compensation calculated with power targets and tonnage.
PSD Wear Compensation: Fine adjustments for wear compensation calculated with PSD targets with feedback from camera/laser scanner.
Feed Camera/Laser Option: Detection of oversize boulders and bridging will alert you to take early/fast decisions.
Plus, intelligent controls automatically adjust the mantle position setpoint, raising it to compensate for liner wear and lowering it in response to over-pressure or over-power events.
Beyond providing high quality equipment and parts, we partner with you in all aspects of your plant process, including equipment loading, screening efficiency, product size needs and material handling. Our process experts assist in designing, installing, commissioning, and auditing your plant to ensure it keeps operating at peak performance.
Monitoring input and output It’s not only the machinery that needs monitoring – the rocks are important too. The TSUV can also include three systems to analyse crusher input and output, which help to avoid blockages, bridging and reduced throughput.
The Gyratory Crusher Oversize Feed Particle Size system uses cameras to analyse the particle size of each truck load prior to it entering the crusher. The system interlocks with the tipping signal light to prevent tipping of oversize rock into the crusher.
The Gyratory Crusher Bridging Particle Size System monitors the crusher feed opening using camera equipment and a particle size analyser to detect bridging/blocking. If a blockage is detected, an alert is sent to the operator and the tipping signal is triggered to prevent further feed entering the crusher.
The Gyratory Crusher Particle Size – Product Belt Camera System analyses the output of the crusher to check the reduction ratio is as expected. If output is oversized, the crusher gap is automatically adjusted.
Imbalanced crusher loading resulting in poor production
Properly balanced crusher loading resulting in maximum production
Our team will evaluate the following typical concerns and help deliver the best solution:
Liner profile wear Crusher load sharing Oversize and waste material Recirculating load Wear rates Power draw
The end result? A productivity and profitability boost thanks to improvements in product quality, wear part utilisation and equipment availability.
Dedicated design capabilities
Our materials handling engineering team now brings seamless capability to design stations dedicated to the 'Top Service' TSUV crushers.
From fixed stations to traditional truck-fed semi-mobile stations to low profile semi-mobile stations, we have the solution you need.
The TSUV crushers offer benefits that no other crushers can offer when you consider the following:
Despite their higher power handling capabilities, TSUV crushers offer the lowest dynamic loadings in their class. This leads to less steelwork, less civils and therefore no need to compromise on the crusher you really need for the job at hand.
The TSUV range greatly decreases the maintenance cycle and negates the need and additional height required for a costly eccentric maintenance cart.
Our complete range of TSUV Gyratory Crushers can be mounted on fixed and semi-mobile steel plants, giving you the freedom and flexibility to design your plant the way you want to.
Not enough height to go direct dump? Opt for the “Low-Profile” configuration, which can accommodate your civil constraints.
30 72
BY FLSmidth
BY CLIENT
24350 6500
12 00
TLC for primary crushers
The team at FLSmidth has been working with a number of customers recently to eliminate unexpected crusher shutdowns and to optimise equipment reliability. Manager of Life Cycle Services Charlie Madsen was happy to share this knowledge. “Planned major maintenance predominantly means liner changeouts,” he said. “But generally, the crusher will be shut down for two mantle changes and one concave change per year. Mantle changes can be done in approximately 24 hours and a concave with a mantle change in four to seven days depending on factors such as mine location and site specifics.
“These are characteristics that can change over the lifespan of a pit or orebody, requiring constant attention to liner material choice and profiles. This ensures wear patterns and wear loss are kept at the optimum level and secures lowest cost per metric ton in operation,” Madsen said. “FLSmidth mitigates wear rates by using different types of manganese in its liners, upgrading to chrome- moly where necessary. White iron can also be advantageous.”
Combining this with the optimisation of liner profiles, throat/chamber design and operations on-site for feed characteristics tends to give the most successful result, and changes in the above can extend liner profiles and throughput over a lifetime by up to 500,000 mt in some cases. This is obviously welcomed by the customer as downtime is cut and maintenance costs reduced. Madsen explained: “There are an abundance of checks that should be carried out fully and thoroughly in preventative maintenance inspections and with a computerised maintenance management system (CMMS). These, in combination with customer training, can reduce maintenance times and cut unplanned failures. It also enables more consistent scheduling of work activities, planned shutdowns and parts supply.”
“Hydroset replacements are planned/recommended anywhere between one and five years, again depending on site-related variations. General maintenance is hard to time, but an educated estimate would be something along the lines of three to four days every half year. Maintenance schedules are planned through information, data, and trending of wear and components.” Rate of wear and wear characteristics are typically determined by the orebody type, work index, abrasiveness and fracture rate, as well as throughput.
Maintaining the open side setting (OSS) is typically done by operators with a control system that shows the main shaft position at all times. FLSmidth’s automation team has designed new software that can carry out optimisation of the main shaft position based upon a number of instruments that maximise throughput, power/ wear and final product. “Calibration of the main shaft is an infield exercise, as manual verification and measurements have to be conducted in order to calibrate and scale the electronic equipment,” said Madsen. “By optimising the main shaft position, we create a more effective and constant wear profile, which allows the end user to get full wear out of liners.”
FLSmidth is developing a comprehensive maintenance management system for its Excel-Raptor cone and gyratory crusher lines. “We also we have a self-aligning main shaft, which improves on installation times, and more importantly, safety and suspended loads,” Madsen added. “We are also the only OEM with a fully top service gyratory, which improves on maintenance downtime and saves on building and construction designs and sizes.” The team has designed rotable shell segments to reduce concave liner changeout times, and the spider removal jacks are threaded into the shell rather than being free standing to reduce manual handling requirements and improve ergonomic positioning for staff.
Charlie Madsen, Manager of Life Cycle Services, FLSmidth spoke to Engineering & Mining Journal about our approach to preventive maintenance.
Copyright © 2020 FLSmidth. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth. This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time. M
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FLSmidth A/S Vigerslev Allé 77 2500 Valby Denmark
Tel. +45 36 18 10 00 Fax +45 36 30 18 20 [email protected]
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